Details

The Damper Test Bench is a state-of-the-art hydraulic testing system designed to evaluate the performance, durability, and efficiency of damper assemblies used in military, aerospace, and industrial vehicles. Engineered for high-precision testing, this system measures jounce (compression) and rebound (expansion) characteristics, ensuring optimal shock absorption and suspension reliability. Equipped with a powerful hydraulic system, advanced data acquisition (DAQ) technology, and automated testing capabilities, the Damper Test Bench delivers accurate real-time pressure vs. flow analysis. With up to 150 bar pressure and 200 LPM flow rate, it replicates extreme operating conditions to verify compliance with industry standards.

The Damper Test Bench is a specialized high-performance hydraulic testing system designed to evaluate the differential pressure characteristics and performance efficiency of damper assemblies used in Hydraulic Suspension Units (HSU). This bench plays a critical role in testing the shock absorption capabilities and rebound characteristics of dampers, ensuring their reliability in high-impact applications, particularly in military vehicles like the K9 VAJRA Tank.

A damper assembly functions as an internal pressure regulator that controls the partitioning of hydraulic oil within the main cylinder. It absorbs shocks and jerks during vehicular motion, thereby providing a smooth jounce (compression) and rebound (expansion) effect. The Damper Test Bench subjects the damper to controlled hydraulic forces to simulate real-world operational conditions, ensuring that the component meets stringent quality and durability standards.
The system applies up to 150 bar of hydraulic pressure and delivers a flow rate of up to 200 LPM on both sides of the damper cage to evaluate its performance in extreme conditions. The test process includes real-time monitoring, automated data acquisition, and graphical representation of pressure vs. flow characteristics, followed by the generation of a detailed test report.

2. Functional Capabilities and Key Features
2.1 Performance Characteristics
 • Assessment of damper effectiveness in maintaining pressure differentials.
 • Simulation of jounce (compression) and rebound (expansion) cycles under varying hydraulic conditions.
 • High-precision pressure and flow monitoring using integrated sensors.
 • Automatic data acquisition (DAQ) system for recording test results and generatingcomprehensive reports.
 • Real-time graphical representation of test data, aiding in performance evaluation.
 • Configurable test parameters to accommodate different damper specifications.

2.2 Structural and Operational Design
 • Robust frame structure that securely houses the test components.
 • Cage assembly for damper placement, ensuring proper positioning during testing.
 • Hydraulic power pack with dual motors and external gear pumps to generate the required pressure and flow conditions.

 • Advanced filtration system (10-micron filter) to maintain hydraulic oil cleanliness and prevent contamination.
 • Temperature regulation system to maintain optimal operating conditions.
 • Variable Frequency Drive (VFD) system for precise motor speed and flow rate control.

3. Technical Specifications
 • Maximum Test Pressure: 150 bar
 • Flow Rate: Up to 200 LPM
 • Power Pack Motor Rating: 40 HP (each) × 2 motors
 • Pump Type: External gear pump (110 LPM per pump)
 • Total Combined Flow Rate: 220 LPM
 • Reservoir Capacity: 200 liters with monitoring systems
 • Filtration System: 10-micron high-pressure filter
 • Control System: DAQ-based automation with LabView software
 • Variable Frequency Drive (VFD): ABB Variable Frequency Drive (VFD) for dynamic flow control
 • Pressure Measurement: Manual gauges and electronic transmitters
 • Direction Control Valve: Pilot-operated NG25 valve
 • Cooling System: In-line air-cooled oil cooling unit
 • Test Parameters: Configurable per unit specifications

4. System Components and Working Mechanism
4.1 Power Pack
The power pack serves as the primary hydraulic energy source, consisting of two 40 HP motors operating in conjunction with external gear pumps. Each pump delivers 110 LPM, providing a combined flow of 220 LPM.

Features:
 • Pressure regulation via a safety valve system to prevent excessive force application.
 • Integrated pressure gauge to provide real-time monitoring.
 • 200-liter hydraulic oil reservoir with built-in:
 • Level switch to prevent operation under insufficient oil conditions.
 • Temperature gauge and transmitter for active temperature monitoring.
 • Tank top filter, filler breather, and level gauge to ensure proper oil quality.
 • 10-micron high-pressure filter to eliminate contaminants and protect system components.
 • Air-cooled oil cooling system to maintain the operational temperature within safe limits.

4.2 Damper Panel
The damper panel is responsible for routing hydraulic fluid to the test bench via high-pressure hoses and manifolds.

Features:
 • Hydraulic hoses (Parker make) ensure robust and leak-proof connections.
 • Panel manifold for systematic pressure distribution.
 • Manual pressure gauges and electronic transmitters for precise measurement of differential pressure across the damper.
 • Pilot-operated Direction Control Valve (NG25) to enable controlled flow switching.
 • Rexroth solenoid-operated pilot valve to automate hydraulic actuation.

4.3 Variable Frequency Drive (VFD) Panel
The VFD panel contains an ABB Variable Frequency Drive that allows for dynamic motor speed control.

Features:
 • Fine-tuned control over hydraulic flow through real-time motor RPM adjustments.
 • Automated clockwise and counterclockwise motor control to regulate jounce and rebound cycles.
 • Digital flow rate and pressure monitoring for optimized test conditions.

5. Testing Process and Operation

5.1 Manual Mode
Before starting the test, the operator ensures that the damper is securely placed in the test cage.
The testing process involves:
1. Switching on the VFD panel and ensuring all emergency stops are disengaged.
2. Activating flow from A to B direction to test jounce characteristics.
3. Engaging the loading valves (red indicator light turns on).
4. Gradually increasing the flow rate to simulate operating conditions.
5. Observing and recording the pressure difference at different flow rates.
6. Reversing flow direction to B to A for rebound testing.
7. Repeating the pressure and flow measurement steps.
8. Slowly reducing the flow rate to zero before turning off the system.

5.2 Automatic Mode
For fully automated operation, the test bench uses a DAQ-based control interface integrated with LabView software. The operator follows these steps:
1. Powering on the VFD panel and DAQ system.
2. Selecting "DAMPER TEST" from the LabView menu.
3. Entering test parameters, including unit part number, serial number, pressure settings, and flow rate.
4. Engaging loading knobs and verifying that the indicator light is activated.
5. Starting the main pump to initiate the automated test cycle.
6. The system automatically executes jounce and rebound tests while capturing test data.
7. Generating real-time graphs and a final test report.

6. Safety Protocols
Operators must comply with the following safety guidelines:
 • Ensure the main ball valve is open before running the pump.
 • Pressure regulator settings should not exceed 110 bar without authorization.
 • Secure all bolts and hydraulic fittings to prevent leaks.
 • Maintain oil level and temperature within safe operational limits.
 • Follow proper shutdown procedures in case of emergencies.
 • Ensure adequate grounding and insulation to prevent electrical hazards.
 • Do not touch exposed electrical components while the machine is operating.

7. Maintenance and Troubleshooting
To ensure continuous and reliable operation, regular maintenance is required. Common troubleshooting scenarios include:
 • Power pack not turning on: Verify the main power supply and electrical connections.
 • Motor not starting from DAQ: Ensure the Local/DAQ switch is set to DAQ mode.
 • Pump failing to build pressure: Adjust the pressure regulator settings.
 • No analog input detected: Confirm that the DAQ panel's MCB is switched on.
 • Flowmeter not registering flow: Check if the loading valves are properly engaged.
 • Filter clogging warning light on: Inspect and replace the 10-micron filter element if necessary.
 • Hydraulic leaks detected: Tighten all fittings and connections to eliminate leaks.

8. Conclusion
The Damper Test Bench is a cutting-edge hydraulic testing solution designed to validate damper performance in military, aerospace, and heavy vehicle applications. By leveraging advanced hydraulic control, automated data acquisition, and precision monitoring, this system ensures that critical damping components meet the highest industry standards for reliability and efficiency.